Methods for using parallel flow reactor having improved thermal control

ABSTRACT

Parallel flow chemical processing systems, such as parallel flow chemical reaction systems are disclosed. These systems are adapted to simultaneously and independently vary temperature between separate flow channels, preferably by employing separate, individual heating elements in thermal communication with each of four or more parallel flow reactors. The flow reactors are preferably isolated from each other using a thermal isolation system comprising fluid-based heat exchange. In preferred embodiments, the axial heat flux can be fixedly or controllably varied.

This application is a divisional of U.S. application Ser. No. 10/094,257filed on Mar. 7, 2002, which claims priority to co-owned, U.S. Ser. No.60/274,065 entitled “Parallel Flow Reactor Having Improved ThermalControl” filed Mar. 7, 2001 by Bergh et al. both of which areincorporated herein by reference for all purposes.

BACKGROUND OF INVENTION

The present invention generally relates to materials science research,and specifically, to combinatorial (i.e., high throughput) materialsscience research directed toward the identification and/or optimizationof new materials. The invention particularly relates, in preferredembodiments, to apparatus and methods for optimizing chemical reactionsystems, such as chemical reaction systems involving heterogeneouscatalysts.

In recent years, significant efforts have been extended towarddeveloping parallel systems, such as parallel reactors, for the purposeof screening different materials, such as heterogeneous catalysts, forparticular properties of interest, such as catalysis. U.S. Pat. No.5,985,356 to Schultz et al. discloses synthesis and screening arrays ofmaterials in parallel for catalysis, and U.S. Pat. No. 6,063,633 toWillson discloses parallel flow reactors, and parallel screeningtechniques (e.g., thermography, chromatography, etc.) for evaluatingcatalysis. A substantial portion of such effort has, however, focussedon apparatus and methods for evaluating compositional space of thematerials (e.g., heterogeneous catalysts) of interest, while only arelatively small portion of such effort has been directed towardapparatus and methods for evaluating other parameter spaces—in additionto compositional space. More specifically for example, in the context ofheterogeneous catalysis research, only limited attention has beenfocused on the development of apparatus and methods for high-throughput,parallel optimization of important parameters such as catalyst (orcatalyst precursor) processing conditions and reaction conditions.

A number of parallel flow reactors are known in the art. For example,PCT application WO 98/07206 (Hoechst) discloses a parallel flow reactorsaid to be useful for evaluating chemical reactions using minaturizedreactors. U.S. Pat. No. 6,149,882 to Guan et al. discloses, among otherfacets, a parallel flow reactor for screening of heterogeneous catalystsin which feed flow is controlled using flow restrictors such ascapillaries to obtain substantially the same flow in each of thereaction channels. More recently, WO 00/51720 (Symyx Technologies, Inc.)discloses a parallel flow reactor design that addresses severalsignificant technical challenges, including flow distribution challengesfor parallel screening of catalysts in very large numbers. Otherreferences, including WO 97/32208 (Technology Licensing Co., Ltd.), DE19809477 (Schuth), WO 99/41005 (BASF) and DE 19806848 (BASF) likewisedisclose parallel flow reactor configurations. Various of theaforementioned references contemplate control of the reactiontemperature in the parallel reactors, including for example, applying athermal gradient across a plurality of reactors to investigatetemperature effects on a reaction of interest. Typically, thermalcontrol is effected for all of the reaction vessels, collectively, orfor a subset of the reaction vessels as modules or zones.

These and other reactor designs known in the art do not, however,specifically address approaches or contemplate apparatus forinvestigating and/or optimizing reaction temperature—simultaneously andindependently—in relatively closely-packed, highly parallel reactors. Asreactor dimensions become reduced, and as the spatial density ofreactors increases, significant thermal cross-talk between reactionvessels can be a substantial obstacle for achieving simultaneous andindependent temperature control in such reaction systems.

Hence, there remains a need in the art to overcome such deficiencies,and to provide for parallel flow reactors having robusttemperature-control capabilities for systematically investigating and/oroptimizing chemical processes with respect to temperature.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide apparatusand methods for more efficient identification and/or optimization ofmaterials and/or temperature conditions in chemical processing systems(e.g., chemical reaction systems), where temperature can beindependently significant with respect to performance in the applicationof interest.

Briefly, therefore, the present invention is directed to parallel (e.g.,multi-channel) chemical processing systems, and especially, chemicalprocessing Microsystems. Although primarily discussed and exemplifiedherein in the context of parallel reactors, and especially parallelmicroreactors, it is to be understood that the invention hasapplications in other chemical processing systems (e.g., mixing systems,separation systems, material-processing systems, etc.), some of whichare discussed in varying detail below.

The invention is directed, in one embodiment, to parallel reactionsystems having the capability to simultaneously and independently varytemperature between separate channels. The parallel flow reactionsystems can generally include a reactor module that comprises four ormore parallel flow reactors having separate and independent temperaturecontrol for each of the four or more reactors. Preferably, thetemperature control system is adapted to provide individually variabletemperature differences of at least about 5° C., preferably at leastabout 10° C. as compared between four or more spatially adjacentreactors. Advantageously, in some embodiments, the thermal controlsystem of the reaction system is capable of providing even highertemperature differences between spatially adjacent reactors—such as atleast about 20° C., at least about 50° C., at least about 100° C., atleast about 150° C. or at least about 200° C.

The chemical reaction system of the invention generally comprises fouror more reactors and a fluid distribution system. Each of the reactorscomprises a surface defining a reaction cavity for carrying out achemical reaction, an inlet port in fluid communication with thereaction cavity, and an outlet port in fluid communication with thereaction cavity. The reaction cavity has a volume of not more than about100 ml, preferably not more than about 50 ml, 20 ml, or 10 ml, and insome applications, not more than about 7 ml, 5 ml, 3 ml, 1 ml, 100 μl,10 μl or 1 μl. The reaction volume can be the same or different for thefour or more reactors. The fluid distribution system can simultaneouslysupply one or more reactants from one or more external reactant sourcesto the inlet port of the reaction cavity for each of the four or morereactors, and can discharge a reactor effluent from the outlet port ofeach such reaction cavity to one or more external effluent sinks. Assuch, the invention generally comprises a four- (or more-) channelparallel flow reactor, preferably of micro-scale (e.g, not more thanabout 1 ml, for purposes hereof). The reaction system can furthercomprise a detection system, integral or separate from the reactionsystem, for evaluating the reactions, for example, by detecting one ormore reaction products or unreacted reactants in the effluent streams ofthe four or more reactors.

Significantly, in a particularly preferred embodiment, the temperatureof each of the four or more reaction vessels is simultaneously andindependently controlled using separately-controlled heating elements(e.g. resistive heating elements such as coil heaters) around each ofthe four or more reactors, while thermal isolation between the four ormore reactors is accomplished by fluid-based heat exchange with anexternal heat sink. Preferably, the fluid heat exchange includes forcedconvection of a fluid between isolated, individually-heated reactors.The fluid is preferably a gas, although a liquid is suitable for someembodiments. In particularly preferred embodiments, the fluid-type heatexchanger includes at least one heat-exchange fluid inlet (with fresh,typically colder fluid) in the vicinity of the reaction zone of thereactors.

In preferred embodiments, the heat flux being applied to each of thereactors has a spatial profile, preferably an axial profile (taken alongthe length of the flow reactor, with the direction of flow) that can bevaried (fixedly varied, or controllably varied). Preferably, theheat-flux provided by the heating elements can be axially varied toachieve a substantially uniform axial temperature profile. Specifically,the heating elements can be configured and arranged to achieve an axialtemperature profile (for the operating temperatures of the reactors,discussed below) that varies by less than about 10%, preferably lessthan about 5%, more preferably less than about 3% and most preferablyless than about 1% over a dimension (e.g., the length) of the reactionzone that corresponds to the axial flow path of the reactants throughthe flow reactor. The axially-variable heat-flux provided by the heatingelements can compensate for variations in the heat-flux in the reactionzone (e.g., hotter regions near the center of the reaction zone orgenerally, other hot-spots), as well as variations in the heat-fluxprofile associated with the circulating heat-exchange fluid cooling thereactors. In another embodiment, the heat flux can also be variedspatially over the array (e.g., as compared between different reactors),and to compensate for the varied locations of the four or more reactorsrelative to other reactors and to the external environment (e.g.reactors that are centered in the array versus reactors near an externaledge of the reactor module). Hence, design and/or control of the heatingelements for each of the reactors can effect a substantiallyaxially-uniform temperature profile for each of the four or morereactors independently, and without regard to the relative locationwithin the array of reactors.

The invention is particularly advantageous for reaction systems havingthermal management challenges—such as exist for such reactor modules inwhich the four or more flow reactors are close-packed—that is, in whichthe four or more reactors have a spatial density, taken along one ormore cross-sections of a two-dimensional array, of not less than about 1reactor/100 cm², preferably not less than about 1 reactor/50 cm², morepreferably not less than about 1 reactor/10 cm², and, in someapplications, not less than about 1 reactor/cm², not less than about 2reactors/cm², not less than about 1 reactor/mm². In alternativeembodiments having a linear array or curvilinear array of reactors, thespatial density, taken along a centerline of the linear array orcurvilinear array, can be not less than about 1 reactor/10 cm,preferably not less than about 1 reactor/7.5 cm, more preferably notless than about 1 reactor/3 cm, and, in some applications, not less thanabout 1 reactor/cm, not less than about 2 reactors/cm, or not less thanabout 1 reactor/mm. The close-packed nature of the reactors can also becharacterized, especially for reactors comprising elongated reactionvessels, with respect to spacing of the reactors. In one embodiment, thecenter-to-center distance between adjacent reactors, taken at across-section substantially perpendicular to the direction of flow, ispreferably not more than about 10 times the diameter of the reactor (forreactors with circular cross-sections), or more generally, not more thanabout 10 times the length of a chord intersecting the center of thereactor (for reactors having a non-circular geometry (e.g., hexagon,octagon, etc.). Preferably in such embodiment, the center-to-centerdistance between adjacent reactors, taken at a cross-sectionsubstantially perpendicular to the direction of flow, is preferably notmore than about 7 times, and more preferably not more than about 5 timesthe diameter (or more generally, the length of a chord intersecting thecenter of the reactor). The center-to-center distance between adjacentreactors can preferably range from about 1.5 times to about 10 times,more preferably from about 2 times to about 7 times, and most preferablyfrom about 3 times to about 5 times the diameter (or more generally, thelength of a chord intersecting the center of the reactor), and isespecially preferably about 3 times or about 4 times the diameter orrelated chord length. This is particularly true for higher numbers ofclose-packed reactors (e.g., having a spatial density of not less thanabout 1 reactor/100 cm² (two-dimensional array) or not less than about 1reactor/10 cm (linear array or curvilinear array), or characterized by acenter-to-center distance of not more than about 10 times the diameter(or more generally, the length of a chord intersecting the center of thereactor), such as six or more reactors, eight or more such reactors,twelve or more such reactors, sixteen or more such reactors, or more (asdescribed below) and especially where at least one, and preferably twoor more of such higher numbers of reactors are spatially nested—that is,are configured and arranged in a two-dimensional array (orthree-dimensional array) having at least one reactor that is aboutequidistant from at least three other reactors, and is preferably aboutequidistant from at least four other reactors. For example, a spatiallynested reactor can be arranged internally to peripheral reactors (e.g.,an outer ring of peripheral reactors), such that each spatially nestedreactor has at least three adjacent reactors, each of which ispreferably substantially the same distance from the spatially nestedreactor.

The invention is also directed to methods of using such reactionsystems, and generally, such chemical processing systems, for example,for evaluating catalytic reactions at various process temperatures in aparallel flow chemical reactor. The method of the invention cancomprise, in a preferred embodiment, simultaneously feeding reactants toa set of four or more parallel reactors through a fluid distributionsystem. Each of the four or more reactors comprise a catalyst effectivefor catalyzing a reaction of interest, with the catalyst beingsubstantially the same or different as compared between the four or morereactors. The catalysts are simultaneously contacted with the reactantswith in each of the four or more reactors under reaction conditionseffective for the reaction of interest. The temperature is preferablycontrolled to be greater than about 100° C. during the course of thereaction. Also, the temperature of the reaction zone of the four or morereactors is independently and controllably varied as compared betweenchannels, such that during the course of the reaction, temperaturedifferences of at least about 5° C., preferably at least about 10° C.are effected as compared between four or more spatially adjacentreactors. In some method embodiments, even higher temperaturedifferences can be run simultaneously between spatially adjacentreactors—such as at least about 20° C., at least about 50° C., at leastabout 100° C., at least about 150° C. or at least about 200° C. Thetemperature control system can comprise four or moreindividually-controllable heating elements in thermal communication withthe four or more reactors, respectively. In preferred embodiments, eachof the four or more reactors can be thermally isolated from each otherduring the course of the reaction by forced-convection heat transferfrom the reactor to the heat-exchange fluid. In preferred embodiments,the heat flux to each of the four or more reactors can be axiallyvaried, to afford substantial flexibility for independently controllingthe axial temperature profile for each of the four or more reactors. Forexample, the method can include varying the axial heat flux of each ofthe four or more reactors such that the axial temperature profile issubstantially uniform, and in some embodiments, such that the axialtemperature profile (for the operating temperatures of the reactors,discussed below) varies by less than about 10%, preferably less thanabout 5%, more preferably less than about 3% and most preferably lessthan about 1% over a dimension (e.g., the length) of the reaction zonethat corresponds to the axial flow path of the reactants through theflow reactor. The catalytic performance of each of the reactions can bedetermined by approaches and instruments known in the art, for example,by monitoring the reaction (e.g., heat of reaction) or by determiningthe composition of reaction products and/or unreacted reactants (e.g.,by infrared spectroscopy, gas chromatography, liquid chromatoagraphy,etc.).

Although especially useful in connection with parallel flow reactors,the temperature-control system disclosed in the aformentioned patentapplication can have applications for control of other types of reactionsystems (e.g., batch reactors, semi-continuous reactors) and/or innon-reaction chemical processing systems such as catalyst pretreatmentprotocols (e.g. calcining of heterogeneous catalysts) or materialcharacterization (e.g. catalyst characterization) where parallel,independent temperature control is desirable, especially wherehigh-temperature contact with a flowing fluid is involved.

The inventions disclosed herein, as well as various permutations andcombinations thereof, can be advantageously and flexibly employed inoptimizing temperature and temperature-dependent properties chemicalsystems of interest, and especially for optimizing post-synthesis,pre-reaction processing/treatment conditions and/or reaction systems forpotential heterogeneous catalysts for a particular reaction of interest.

Other features, objects and advantages of the present invention will bein part apparent to those skilled in art and in part pointed outhereinafter. All references cited in the instant specification areincorporated by reference for all purposes. Moreover, as the patent andnon-patent literature relating to the subject matter disclosed and/orclaimed herein is substantial, many relevant references are available toa skilled artisan that will provide further instruction with respect tosuch subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are schematic views of a four-channel parallel flowreactor (FIG. 1A), with a detail of one of the reaction vessels thereof(FIG. 1B).

FIG. 2A through 2C are cross-sectional or schematic views of atwenty-four channel parallel flow reactor (FIG. 2A) illustrating apreferred temperature control system of the invention, including aschematic heat-exchange fluid flowpath (FIG. 2B) and a detail of onehalf of one of the reaction vessels thereof (FIG. 2C).

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is related to the following patents and/or patentapplications, each of which is hereby incorporated by reference for allpurposes, including for the purpose of combination of various featuresdisclosed in the various related applications to various featuresdisclosed herein, to the highest extent practical, based on theknowledge in the art, and coupled with the guidance of this applicationand the related applications: (1) co-owned U.S. patent application Ser.No. 60/187,566 entitled “Apparatus and Methods for Multi-VariableOptimization of Reaction Systems and Other Chemical ProcessingMicrosystems”, filed Mar. 7, 2000 by Bergh et al., (2) co-owned U.S.patent application Ser. No. 60/229,984 entitled “Apparatus and Methodsfor Optimization of Process Variables in Reaction Systems and OtherChemical Processing Systems”, filed Sep. 2, 2001 by Bergh et al; (3)co-owned U.S. Pat. No. 6,149,882 to Guan et al. entitled “ParallelFixed-Bed Reactor and Fluid Contacting Apparatus and Method”; (4)co-owned, co-pending U.S. patent application Ser. No. 09/518,794,entitled “Chemical Processing Microsystems, Diffusion-MixedMicroreactors and Methods for Preparing and Using Same”, filed Mar. 3,2000 by Bergh et a.; (5) co-owned, co-pending U.S. Ser. No. 09/801,390entitled “Parallel-Flow Process Optimization Reactor” filed Mar. 7, 2001by Bergh et al.; (6) co-owned, co-pending U.S. Ser. No. 09/801,389entitled “Parallel Flow Reactor Having Variable Feed Composition” filedMar. 7, 2001 by Bergh et al.; (7) co-owned, co-pending U.S. Ser. No.60/274,022 entitled “Gas Chromatograph Injection Valve Having MicrovalveArray” filed Mar. 7, 2001 by Bergh et al.; and (8) co-owned, co-pendingU.S. Ser. No. 09/801,430 entitled “Parallel Gas Chromatograph withMicrodetector Array” filed Mar. 7, 2001 by Srinivasan et al.; and (9)co-owned, co-pending U.S. Ser. No. 09/901,858 entitled “Methods forAnalysis of Heterogeneous Catalysts in a Multi-Variable ScreeningReactor” filed Jul. 9, 2001 by Hagemeyer et al. Further reference toseveral of these applications is made below, in the context of thepresent invention.

In a preferred embodiment of the present invention, a chemicalprocessing system is a reaction system that comprises a plurality ofreactors, a fluid distribution system, a temperature control system, andoptionally, a detection system. Generally, the fluid distribution systemcan comprise an inlet subsystem for providing reactants to the reactors,and an outlet subsystem for discharging effluents from the reactors. Afeed-composition subsystem—for providing different feed compositions tothe reactors can be included in the inlet subsystem. A flow-partitioningsubsystem—for providing different flow rates to the reactors, and/or apressure-partitioning subsystems—for providing different pressures inthe reactors, can be included as part of the inlet subsystem and/or inthe outlet subsystem. A feed temperature control subsystem can also beincluded, for temperature control of feed being supplied to thereactors. The temperature control system and the reactors are describedin further detail below. The detection system can be a separate,stand-alone system, or can be integral with the reaction system.

The temperature control system generally comprises four or moreindividually-controllable heating elements, preferably resistive heatingelements, in thermal communication with four or more reactors,respectively. A forced convection cooling system can provide thermalisolation between the four or more reactors.

More specifically, the temperature of each of the four or more reactionvessels is simultaneously and independently controlled usingseparately-controlled heating elements. The heating elements can beresistive heating elements such as resistive coil heaters associatedwith each reactor, or resistive band heaters associated with eachreactor. Alternatively, other types of heating elements can be employed,including for example, fluid-based heat-transfer elements (e.g., moltensalt bath) associated with each reactor, or heating elements involvingirradiation with electromagnetic energy (e.g, localized infraredradiation, visible radiation, microwave radiation, radio frequency (RF)radiation, etc.), such as can be provided using fiber optics, lasers, orother approaches. The heating elements are in thermal communication,preferably via conduction (i.e., thermally conductive communication)with the reactors. The heating elements can be adapted to effect areaction temperature (or generally, chemical processing temperature) inthe individual reactors at temperatures greater than about 50° C.,preferably greater than about 100° C., more preferably greater thanabout 200° C., and in some embodiments, more preferably greater thanabout 300° C. Hence the reaction temperature (or generally, chemicalprocessing temperature) effected by the individually-controlled heatingelements can range from about 50° C. to about 1500° C., preferably fromabout 100° C. to about 1000° C., and more preferably from about 200° C.to about 800° C. In some embodiments, depending on the particularchemical reaction or process of interest, the heating elements can beadapted to effect a reaction temperature (or generally, chemicalprocessing temperature) in the individual reactors ranging from about300° C. to about 600° C. or from about 400° C. to about 600° C.

Thermal isolation between the four or more reactors is accomplished byfluid-based heat exchange with an external heat sink. Preferably, thefluid heat exchange includes forced convection of a fluid betweenisolated, individually-heated reactors. The heat-exchange fluid can be agas (e.g., air or an inert gas with respect to the chemical reaction ofinterest, typically such as nitrogen or argon) or can be a liquid.Forced-convention heat-exchange using a gaseous heat-exchange fluid isparticularly preferred for some embodiments. For example, use of gaseousheat-exchange fluid avoids the potential for phase change of theheat-exchange fluid for higher-temperature operations (although suchphase change may be desirable in other embodiments). Gaseousheat-exchange fluid is particularly advantageous with respect toforced-convection isolation between close-packed reactors, since gassesgenerally allow for the use of higher linear velocities past thereactors (as compared to liquids), and since gasses generally have lowerthermal conductivities (as compared to liquids), which both individuallyand cumulatively have a positive overall effect on heat-transfer out ofand away from the reactors, while eliminating or at least significantlylimiting the extent of thermal cross-talk between adjacent reactors.Regardless of the phase or specific type of heat-exchange fluid, theheat-exchange fluid can have a relatively low thermal conductivity, andpreferably, a relatively high heat-transfer coefficient with the reactorvessels. Heat transfer between the heat-exchange fluid and each of theindividual reactors can be enhanced or optimized using techniques knownin the art. For example, the reactors can be fabricated from materialshaving relatively high thermal conductivity. The external surface of thereactors can be controlled (e.g., by materials selection or byapplication of one or more coatings) to improve or optimize theheat-transfer coefficent at the surface (e.g., by reducing the thicknessof the heat-transfer boundary layer at the surface of the reactor).Also, ultrasonic or megasonic energy can be applied to the reactor toimprove the heat-transfer coefficient at the surface of the reactor. Asanother example, the individual reactors can have an external surfacehaving a relatively high surface area (e.g., greater than the surfacearea of right-cylindrical vessel of the same volume)—such as can beprovided using fins integral with the external surface of the reactor,or in thermally conductive communication with the external surface ofthe reactor. The forced-convection, fluid-based heat-exchanger can beused as the sole means for thermal isolation between theindividually-heated reactors, or alternatively, such fluid-based heatexchanger can be used in combination with solid-material insulation as athermal barrier between vessels. Hence, a thermal isolation subsystem ofthe temperature control system can comprise or consist essentially ofthe fluid-based heat exchanger (as described above and throughout).

The flow path or flow configuration of the heat-exchange fluid is notnarrowly critical, and can be adapted to the particular designobjectives of interest. In general, the heat-exchange fluid flowconfiguration can include one or more fresh (e.g., typically relativelycold) fluid inlets substantially in the vicinity of the hottest part ofthe reactor—typically the center of the reaction zone (e.g., in themidsection of an elongated tube type reactor as shown in FIGS. 1A and1B)—to provide for maximum temperature differential, and accordingly,maximum thermal heat flux from the reaction zone to the heat-exchangefluid. (See, for example, FIG. 2B and the discussion thereof below). Thefluid-based heat exchanger can also have multiple zones, withindependent heat-exchange fluid feeds associated with each zone. Forexample, the fluid-based heat exchanger can have a central zone (takenaxially) that includes at least a central portion (e.g., midsection) ofthe reaction zone of the reactors and one or more end section zones(taken axially), each having independent heat-exchange fluid supply.Particularly preferred embodiments are described hereinafter. Otherembodiments are within the skill in the art.

More specifically, in one particularly preferred embodiment, the four ormore reactors are elongated reaction vessels having a first end sectionsubstantially adjacent the inlet port, a second end sectionsubstantially adjacent the outlet port, and a midsection between thefirst end section and the second end section, with the midsectionincluding a portion of the reaction cavity adapted to contain a catalystand defining a reaction zone. In this case, the forced-convection heatexchanger can comprise one or more heat-exchange fluid inletssubstantially in the vicinity of the midsections of the reactors, suchthat fresh heat-exchange fluid supplied through the heat-exchange fluidinlet can contact the midsection of the reactors before substantialcontact with the first or second end sections thereof. Also, thetemperature control system for such reactors can include aforced-convection heat exchanger that comprises at least threeheat-exchange zones, each of the zones having one or more independentheat-exchange fluid inlets for supplying fresh heat-exchange fluid toits associated zone. A central heat-exchange zone can be adapted toeffect heat transfer from the midsections of the reactors. A first endheat-exchange zone can be adapted to effect heat transfer from the firstend sections of the reactors. A second end heat-exchange zone can beadapted to effect heat transfer from the second end sections of thereactors. Additional heat-exchange zones can also be employed. Themultiple heat-exchange zones can be isolated, or alternatively, can alsohave fluid-communication between zones. For example, in theaforedescribed embodiment, the central heat-exchange zone can be influid communication with each of the first end heat-exchange zone andthe second end heat-exchange zone, such that at least some of theheat-exchange fluid supplied to the central heat-exchange zone can flowto the first end heat-exchange zone and the second end heat-exchangezone after contacting the midsections (near the reaction zones) of thereactors in the central heat-exchange zone.

The thermal control system, comprising the four or moreindividually-controllable heating elements and the forced convectioncooling system considered in combination, provides a robust platform forsimultaneous processing or evaluation of materials at differenttemperatures—even where the reactors are close-packed and/or spatiallynested (i.e., configured and arranged in a two-dimensional array havingat least one reactor that is about equidistant from at least three otherreactors).

Such a thermal control system can be effective, for example, to provideindividually variable temperature differences between spatially adjacentreactors (ΔT_(adjacent)) of at least about such that during the courseof the reaction, temperature differences of at least about 5° C.,preferably at least about 10° C. as compared between four or morespatially adjacent reactors, and in some embodiments, at least about 20°C., at least about 50° C., at least about 100° C., at least about 150°C. or at least about 200° C. Advantageously, such temperaturedifferences can be achieved in arrays of four or more, and preferablyhigher numbers of reactors as described elsewhere herein, where suchreactors are configured and arranged in a close-packed array (e.g., asdescribed above) and additionally or alternatively where such reactorsare configured and arranged in a spatially nested array (e.g., asdescribed above). In preferred embodiments, in which six or morereactors each have a volume of less than about 1 ml and are arranged inan array format, optionally a spatially nested-array format, in eithercase having a spatial density of not less than about 1 reactor/cm², andin which the reaction temperature (or generally, the chemical processingtemperature) is controlled to range from about 300° C. to about 600° C.,the individually variable temperature differences can be at least about10° C. as compared between four or more spatially adjacent reactors, andin some embodiments, at least about 20° C., at least about 50° C., atleast about 100° C.

In preferred embodiments of the thermal control system, consideredseparately and in combination with the above-described preferredembodiments, the heat flux being applied to each of the reactors has anaxial profile, where the axial direction is considered to be taken alongthe length of the flow reactor (i.e., parallel to the direction offlow), such that the heat flux can be spatially varied to achieve adesired temperature profile over a dimension (e.g. length) of thereaction zone. The spatial variance in the thermal flux profile can befixedly varied (without the opportunity for operator change once thereactor design is fabricated), or alternatively, can be controllablyvaried (such that an operator can operationally change axial profilefrom experiment to experiment without redesign of the reactor, butpotentially with or without hardware configuration change to thereactor). In one embodiment, for example, a coil-type resistive heatercan be employed as heating elements, with the number of turns per lineardistance varying along the axial dimension of the reactor. In analternative example, some portions of the heating element could beseparately controlled from other portions thereof (e.g., with highercurrent through one portion of a resistive heating element) so that theaxial thermal flux can be controllably varied. In other approaches, theheating elements could be coupled with spatial variations in insulation,to provide the varied heat flux. Other embodiments are within the skillin the art. Advantageously, axial variation in heat flux can beeffected, according to methods known in the art, to provide asubstantially uniform axial temperature profile over a dimension of thereaction zone. For example, the heat elements can be configured andarranged to provide the capability to effect a variation in the axialheat flux of each of the four or more reactors such that the axialtemperature profile is substantially uniform for each of the four ormore reactors, and in some embodiments, such that the axial temperatureprofile (for the operating temperatures of the reactors, discussedherein) varies by less than about 10%, preferably less than about 5%,more preferably less than about 3% and most preferably less than about1% over a dimension (e.g., the length) of the reaction zone thatcorresponds to the axial flow path of the reactants through the flowreactor. As noted, such variations compensate for variations in theheat-flux profile associated with the chemical reaction in the reactionzone, or that associated with the circulating heat-exchange fluidcooling the reactors. The flexibility afforded by such embodiments canalso compensate for the varied locations of the four or more reactorsrelative to other reactors and to the external environment (e.g.centered reactors versus reactors near an external edge of the reactormodule). Hence, in a particularly preferred approach, the heatingelements for each of the reactors are configured and arranged tocontrollably vary the axial heat flux, such that a substantiallyaxially-uniform temperature profile for each of the four or morereactors can be achieved—independently of each other, and at differenttemperatures with respect to each other (i.e., as compared betweenreactors).

In operation, thermal control system of the invention, and particularly,the four or more heating elements can be independently and controllablyvaried—relative to other heating elements—to provide for controllablyvaried temperature differences between individual reactors of the arrayof reactors. Such variation can be used to investigate and evaluate theeffect of reaction temperature (or generally, processing temperaturessuch as pretreatment temperatures (e.g., calcining temperatures) forheterogeneous catalysts such as mixed-metal oxide catalysts) for areaction of interest (e.g., using substantially the same catalyst ineach reactor). Alternatively, both temperature and one or moreadditional factors affecting the reaction—e.g., catalyst composition orprocess variables such as pressure, feed composition, feed flowrate,space velocity, catalyst loading, catalyst shape, catalyst pretreatmenthistory, catalyst synthesis protocols, etc., can be controllably varied(e.g., in the same set of simultaneous experiments), as taught forexample in the related applications. As noted, other uses (e.g.,generally, materials evaluation, materials characterization, materialstreatment) will be apparent to those of skill in the art.

The invention also includes methods for evaluating catalytic reactionsor for evaluating one or more materials (e.g. catalysts), or forevaluating process conditions (e.g. temperature) in a parallel flowchemical processing system (e.g. parallel chemical flow reactor). Asdescribed, for example, with respect to a parallel flow reactor,reactants are provided to a set of four or more parallel reactorsthrough a fluid distribution system, such that the reactantssimultaneously contact a catalyst or catalyst precursor (e.g.,substantially the same catalyst or a different catalyst as comparedbetween reactors) under reaction conditions effective for the reactionof interest. The flow rates (and associated parameters such as spacevelocity) can be the same or different as compared between reactors. Thetemperature of the reaction zone is independently, and controllablyvaried between the four or more reactors, preferably using the thermalcontrol system described herein, during the course of the reaction. Thereaction products and unreacted reactants (if any) are thensimultaneously discharged from the four or more reactors. The catalyticperformance (e.g., activity and/or selectivity or other figure of merit)can be determined, for example, by monitoring the reaction or bydetermining the composition of reaction products and/or unreactedreactants.

In each of the aforementioned chemical reaction systems, the four ormore reactors can be of any suitable design, including for exampledesigns modeling or substantially modeling continuous-stirred-tankreactors (CSTR's), fixed bed reactors, fluidized bed reactors, plug-flowreactors, channel-type reactors, etc. Designs modeling or substantiallymodeling fixed bed, plug-flow and CSTR-type reactors are preferred. Forexample, in one preferred embodiment, the four or more reactors can beelongated reaction vessels having a first end section substantiallyadjacent the inlet port, a second end section substantially adjacent theoutlet port, and a midsection between the first end section and thesecond end section. The midsection includes a portion of the reactioncavity that is adapted to contain a catalyst (e.g., using frits). Thecatalyst-containing portion of the reactors generally defines thereaction zone. The aforementioned co-pending patent applications of Guanet al. (filed Jun. 9, 1998) and of Bergh et al. (U.S. Ser. No.09/518,794) include preferred reactor and reactor configuration designs.The reactor types in a particular chemical reaction system can beidentical to each other, substantially the same as each other, or varied(e.g., for optimization of reactor-type) in a particular chemicalreaction system. Moreover, the four or more reactors of the reactionsystem are preferably structurally integrated with each other. As oneexample, structurally integral reactors can be formed in a commonreactor block—either a uniform body or a plurality of laminates. Asanother example, structurally integral reactors can include a commonsupport structure (e.g., can be joined substantially adjacent at leastone of their inlet section, outlet section and/or central section by acommon support member). Structural integration between the four or morereactors can also be provided by the forced-convection fluid-heatexchanger of the thermal control system. The reaction system canalternatively comprise, however, four or more structurally separatereactors. In either case, the thermal control system is preferably anintegral system—having structural and/or control features that arecommon to each of the four or more reactors (e.g., commonforced-convection heat-exchange system or common control software orcommon microprocessor).

Each of the aforementioned chemical reaction systems (orprocessing/treatment systems) is preferably a microsystem, in which thevolume of the reaction cavity is not more than about 1 ml. In someembodiments, the reaction cavities can have a volume of not more thanabout 100 μl, not more than about 10 μl, or not more than about 1 μl.The smaller volume reaction systems are particularly advantageous, forexample, with respect to heat transfer characteristics, as well ashandling and interchanging of modular components (e.g., arrays ofdiverse materials, flow-restrictor modules, reactor modules, etc.).

The plurality of reactors are two or more reactors, preferably four ormore reactors, and more preferably nine or more reactors. Higher numbersof reactors, including sixteen, twentyfour, forty-eight or ninety-six ormore reactors are contemplated. When an array of microreactors is usedin connection with the invention, the number of reactors can be hundredsor thousands. Additional general features of the reactors together withpreferred number of reactors, reactor types, types of candidatematerials optionally included within the reactors (especially catalystcandidate materials), variations in composition of the candidatematerials (especially variations in catalysts and/or catalystprecursors) loading/unloading of candidate materials into/from thereactors, configurations of arrays of reactors, planar densities ofreactors, specific reactor designs, and reactor fabrication approachesare as described in the aforementioned co-pending U.S. patentapplications of Guan et al. (U.S. Pat. No. 6,149,882) and Bergh et al.(U.S. Ser. No. 09/518,794), collectively referred to hereinafter as the“Guan et al. and Bergh et al. applications.” Such additional generalfeatures are hereby specifically incorporated by reference.

The format of the array of reactors is not narrowly critical, and cangenerally include both spatially nested and not spatially nestedarrangements, of varying spatial densities. Preferred configurationsinclude spatially nested arrangements of four or more reactors,preferably six or more reactors (or higher numbers, as describedelsewhere herein) having the spatial densities as described above (see,for example, the Summary of the Invention), and additionally oralternatively, preferably having the reactor volumes described herein.Generally, the array of reactors is configured to have at least onespatially nested reactor—that is, at least one reactor that issubstantially equidistant from each of at least three other reactors,preferably from each of at least four other reactors, and mostpreferably from each of at least five other reactors.

Particularly preferred embodiments of the invention will now bedescribed with reference to the several figures.

With reference to FIG. 1A, an integrated chemical reaction system 10 cancomprise a tube-type flow-through reactor design (e.g, analogous to aplug-flow reactor). The reaction system 10 can comprise a plurality ofmicroreactors 600. Each of the reactors 600 can comprise, with referenceto FIG. 1B, an elongated reaction vessel 70 such as a tube or channel.The elongated reaction vessel 70 can be independent of other structureor can be integrated with and formed at, on or in a substrate (e.g., aplurality of laminae or a unitary body). The elongated reaction vessel70 is preferably a stainless steel, ceramic, or quartz tube, and withoutlimitation, preferably has a diameter ranging from about 1 mm to about20 mm, more preferably from about 2 mm to about 10 mm, and mostpreferably from about 4 mm to about 8 mm. The elongated reaction vessel70 can be lined with a liner 72 that is inert with respect to thereaction and reaction conditions being evaluated. The liner 72 can be,for example, a glass liner. The liner 72 can be separable from theelongated vessel 70, or integral therewith—such as a lining deposited asa coating on the inner surface of the elongated vessel 70. Typicalcoating materials include, for example, silica, tungsten, tungstencarbide, titanium and titanium nitride, among others. A candidatematerial (e.g., catalyst or catalyst precursor material) 74 can beprovided to and situated in the elongated reaction vessel 70 in anysuitable form—for catalysts as bulk catalyst or as supportedcatalysts—and in either case in various forms known in the art (e.g.,pellets, beads, particulates, microspheres, substantially uniformmicrospheres, etc). Particle diameters are not narrowly critical, butcan typically range from about 1 μm to about 1 mm, more typically fromabout 10 μm to about 500 μm, and even more typically from about 50 μm toabout 250 μm. The candidate material 74 is preferably held in positionbetween porous end caps 126 (e.g., frits, screens, etc.) situated oneach of the reactor inlet port 71 and reactor outlet port 73.Optionally, an inert filler 76, and preferably an inert filler 76 havingthermal insulating properties can also be provided and situated betweenthe porous end caps 126 and the candidate material 74. Preferably, theinert, thermally insulating filler 76 can be sufficient to maintain theend sections (as shown, generally adjacent to the inlet port 71 andoutlet port 73) at a temperature of less than about 200° C. (tofacilitate the use of lower-temperature seal materials), and hence, toprovide for a temperature difference ranging from at least about 100° C.to at least about 400° C. between the reaction zone (e.g. containingcandidate catalyst material 74) and the reactor inlet port 71 (orreactor outlet port 72). The reactors 600 can be fabricated and/oroperated using manual, semi-automated or automated instruments (e.g.,robotic handling instruments) to provide the candidate materials 74and/or other components of the reactor 600. The reactors 600 shown inFIGS. 1A and 1B can have a low thermal mass, and can thereby provide forrelatively fast thermal cycling for processing/treatment of thecandidate materials (e.g., for calcining of catalysts or catalystprecursors) and for establishing and/or varying reaction conditions inthe reactors 600.

Referring again to FIG. 1A, the material-containing reactors 600 areformed as an array 100 of reactors 600, with each reactor 600 supportednear the reactor inlet port 71 and the reactor outlet port 73 by a firstand second support plates 954, 955. As shown, the plurality of reactors600 are heated by temperature control blocks—shown as heaters980—adjacent to the material-containing portion of the reactors 600 andin thermal communication therewith. As such, the center,material-containing region of the reaction system 10 can be a relatively“hot zone” region, while the inlet and outlet-containing regions can berelatively “cold zone” regions. The temperature can be varied betweenreaction vessels 600, and temperature variations (e.g., gradients) canalso, as desired, be established with multiple temperature zones along asingle reactor 600 and/or along the material-containing portion of asingle reactor 600. Seals, and preferably releasable seals between thefluid distribution system and the reactors 600 can be provided andintegrated into the support plates 954, 955. Advantageously, such adesign allows for the fluid-distribution seals to be located in the coldzones—and outside of the hot-zone, thereby providing for greaterflexibility with respect to sealing materials, etc. Exemplary sealingmaterials include graphite, fluoropolymer, metal seals, or other sealmaterials. Reactants 20 can be provided to the reactors 600 through aninlet distribution subsystem 500 in fluid communication with themicroreactors 600. The inlet distribution subsystem 500 can comprise afirst set 510 of inlet flow restrictors, and optionally, afeed-composition varying subsystems (not shown in FIG. 1A). Aftercontacting the candidate materials (e.g., catalysts) 74 under thevariably controlled reaction conditions, reactor effluents 60 are passedthrough an outlet (discharge) distribution subsystem 501, and further toan external distribution (waste) system. The outlet distributionsubsystem 501 can comprise a second set 520 of outlet flow restrictors.The inlet and outlet distribution subsystems 500, 501 can be thermallyisolated from the microreactors 600 (e.g., by air or other insulatinggas, by temperature control block, etc.) Evaluation of the candidatematerials can be determined by analysis of reaction products, forexample, by sampling of the reactor effluent streams as described aboveand/or in connection with the Guan et al. and Bergh et al. applications.The chemical reaction system can optionally be contained within a heatedenvironment (e.g, an oven 750, and in operation, a heatedoven)—particularly when liquid reagents are employed—to provide foradditional thermal energy to keep the feed stream and effluent streamsin the vapor phase.

In a preferred embodiment, the invention is exemplified by a twenty-fourchannel, parallel-flow reaction system for effecting twenty-foursimultaneous reactions. Each of the twenty-four reactors can be afixed-bed type flow reactor, allowing for evaluation of candidatecatalysts under varied process conditions. The reactor can also includea temperature-control subsystem for controlling, individually, thetemperature of each of the twenty-four reactors.

The reactor module 4600, shown as a cut-away schematic in FIG. 2A,comprises a 4×6 array of twenty-four reactor tubes 4610 individuallysupported in a reactor frame 4605. Each tube has a reaction volume ofabout 1 ml. Each of the reactor tubes 4610 can be individually heatedusing resistive coil heaters 4620 (e.g. Watlow Mini-K-ring). Thermalisolation between reactor tubes 4610 is achieved using fluid-type heatexchanger to cool the inter-reactor volume within the reactor frame4610. FIG. 2B shows a general schematic flow diagram for theheat-exchange fluid flowpath through the array of reactors 4610.Referring to both FIGS. 2A and 2B, preferably, the cooling medium is airor inert gas, and is fed into the reactor module 4600 substantially atthe midsection thereof—adjacent the central portion of the reaction zoneof the reactors 4610, in a first, primary central heat-exchange zone.The heat-exchange medium contacts each of the reactors substantially atits center, then generally splits and flows towards each end of thereactors (4612, 4614). Plate cooling fluid (e.g. air) is also fedthrough the top member 4606 and bottom member 4607 of the reactor frame4605, specifically through heat-exchange channels 4608 formed therein,in a set of secondary, end heat-exchange zones. Advantageously, asdescribed in greater detail above, and with reference to FIG. 2C, theheat flux associated with the resistive coil heaters 4620 can be axiallyvaried to account for heat variations due to the reaction, and tobalance heat removal by the cooling media such that a substantiallyaxial uniform temperature profile is obtained. FIG. 2C shows a detail ofone half of the resistive coil heaters 4620, with axial variation in thenumber of winds of the resistive heating wire. The wire connection 4630allows for individual, controlled heat input for each of the reactors.The feed gas flows into the reactor tube inlet 4612, and optionallycontacts a catalyst (e.g., supported in the reactor tube using frits(not shown)) under reaction conditions to effect the chemical reactionof interest. The reaction products and unreacted reactants aredischarged through the reactor tube outlet 4614.

Although described particularly in connection with gas and liquid phasechemical reaction systems, the present invention has, as noted above,applications in other areas, including for example, as a paralleladsorbent system, extraction system and/or solubilization systems forresearch and development in, for example, the gas processing fields,environmental applications or in pharmaceutical manufacturing. Thechemical processing systems described herein can also be employed, forexample, in connection with solid-state chemistry and solid-statematerial research and development. In any of the aforementionedapplications, evaluation of candidate materials and/or of processingconditions can be effected by characterizing one or more properties ofthe plurality of candidate materials (e.g., crystal structure) afterprocessing in the chemical processing system.

In light of the detailed description of the invention and the examplespresented above, it can be appreciated that the several objects of theinvention are achieved.

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the invention.

1. A parallel flow reaction system for effecting four or moresimultaneous reactions in four or more reaction channels, the reactionsystem comprising four or more reactors configured and arranged in anarray with a center-to-center distance between adjacent reactors of notmore than about 10 times the diameter of the reactor for reactors withcircular cross-sections, or not more than about 10 times the length of achord intersecting the center of the reactor for reactors having anon-circular cross-section, each of the four or more reactors comprisinga surface defining a reaction cavity for carrying out a chemicalreaction, an inlet port in fluid communication with the reaction cavity,and an outlet port in fluid communication with the reaction cavity, thefour or more reactors being adapted for effecting a chemical reaction atreaction temperatures of greater than about 100° C., a fluiddistribution system for simultaneously supplying one or more reactantsto the reaction cavity of each of the four or more reactors, and fordischarging a reactor effluent from the outlet port of each suchreaction cavity to one or more effluent sinks, and a temperature controlsystem comprising four or more individually-controllable heatingelements in thermal communication with the four or more reactors,respectively, for simultaneously and individually controlling thetemperature of each of the four or more reactors, the temperaturecontrol system being adapted to provide individually variabletemperature differences of at least about 10° C. as compared betweenfour or more spatially adjacent reactors.
 2. The reaction system ofclaim 1 wherein each of the four or more heating elements provides anaxially-varying heat flux to the reaction cavity of its respectivereactor.
 3. A parallel flow reaction system for effecting four or moresimultaneous reactions in four or more reaction channels, the reactionsystem comprising four or more reactors, each of the four or morereactors comprising a surface defining a reaction cavity for carryingout a chemical reaction, an inlet port in fluid communication with thereaction cavity, and an outlet port in fluid communication with thereaction cavity, the four or more reactors being adapted for effecting achemical reaction at reaction temperatures of greater than about 100°C., a fluid distribution system for simultaneously supplying one or morereactants to the reaction cavity of each of the four or more reactors,and for discharging a reactor effluent from the outlet port of each suchreaction cavity to one or more effluent sinks, and a temperature controlsystem comprising four or more individually-controllable heatingelements in thermal communication with the four or more reactors,respectively, for simultaneously and individually controlling thetemperature of each of the four or more reactors, each of the four ormore heating elements providing an axially-varying heat flux to thereaction cavity of its respective reactor.
 4. The reaction system ofclaims 1 or 3 wherein the temperature control system is adapted toprovide individually variable temperature differences of at least about50° C. as compared between four or more spatially adjacent reactors. 5.The reaction system of claims 1 or 3 wherein the temperature controlsystem is adapted to provide individually variable temperaturedifferences of at least about 100° C. as compared between four or morespatially adjacent reactors.
 6. The reaction system of claims 1 or 3wherein the four or four or more heating elements are resistive heatingelements.
 7. The reaction system of claims 1 or 3 wherein the volume ofthe reaction cavity of the four or more reactors is not more than about1 ml.
 8. The reaction system of claims 1 or 3 wherein the four or morereactors comprise an array of four or more reactors configured andarranged such that the spatial density of reactors in a two-dimensionalarray is not less than about 1 reactor/10 cm², or in a linear orcurvilinear array is not less than about 1 reactor/3 cm.
 9. The reactionsystem of claims 1 or 3 wherein the four or more reactors are configuredand arranged in an array having at least one reactor that is aboutequidistant from at least three other reactors.
 10. The reaction systemof claims 1 or 3 wherein the four or more reactors each have a reactioncavity volume of not more than about 1 ml, the four or more reactorsbeing configured and arranged in an array having at least one reactorthat is about equidistant from at least three other reactors such thatthe spatial density of four or more reactors in the array is not lessthan about 1 reactor/10 cm², and the temperature control system isadapted to provide individually variable temperature differences of atleast about 50° C. as compared between four or more spatially adjacentreactors.
 11. The reaction system of claim 10 wherein the four or morereactors are configured and arranged such that the spatial density offour or more reactors in the array is not less than about 1 reactor/1cm².
 12. The reaction system of claims 1 or 3 wherein the four or morereactors comprise elongated reaction vessels.
 13. The reaction system ofclaims 1 or 3 wherein the four or more reactors are elongated reactionvessels having a first end section substantially adjacent the inletport, a second end section substantially adjacent the outlet port, and amidsection between the first end section and the second end section, themidsection including a portion of the reaction cavity adapted to containa catalyst and defining a reaction zone.
 14. The reaction system ofclaims 2 or 3 wherein the heating elements associated with the four ormore reactors are adapted to provide a substantially uniform temperatureprofile along the direction of reactant flow through a reaction zone ofthe reactors.
 15. The reaction of claim 14 wherein the heating elementsassociated with the four or more reactors are adapted to provide atemperature profile that varies by less than about 5% through thereaction zone of the reactors.